Hydrogen Generator Model HPNM – 2...Hydrogen Generator Instruction Manual Introduction 3 Introduction Scope of the manual This manual provides operation and maintenance instructions

Hydrogen Generator Model HPNM – 2

MATHESON TRI-GAS 166 Keystone Drive

Montgomeryville, PA 18936 Phone: 215-641-2700

Fax: 215-619-0458 Email: [email protected]

mailto:[email protected]

Hydrogen Generator Instruction Manual Introduction

2

Index INDEX ................................................................................................................................................................. 2

INTRODUCTION............................................................................................................................................... 3 SCOPE OF THE MANUAL..................................................................................................................................... 3 SPECIFICATIONS ................................................................................................................................................ 3 NOTES ON FCC COMPLIANCE............................................................................................................................ 4 CORRECT USE.................................................................................................................................................... 4 PACKING LIST.................................................................................................................................................... 5

DESCRIPTION................................................................................................................................................... 6

INSTALLATION................................................................................................................................................ 7 RECEIVING THE GENERATOR ............................................................................................................................. 7 PLACING THE GENERATOR................................................................................................................................. 7 SYMBOLS USED ON THE GENERATOR................................................................................................................. 7 GAS CONNECTIONS............................................................................................................................................ 7 ELECTRICAL CONNECTIONS............................................................................................................................... 8 REMOTE CONNECTIONS (OPTIONAL).................................................................................................................. 8 CASCADING (OPTION) ....................................................................................................................................... 9

INITIAL START-UP........................................................................................................................................ 10 FILLING THE WATER TANK .............................................................................................................................. 10 INSTALLING THE DEIONIZER BAG .................................................................................................................... 11 OPERATION ..................................................................................................................................................... 12

MAINTENANCE.............................................................................................................................................. 16 ROUTINE MAINTENANCE ................................................................................................................................. 16 RETURNING THE UNIT...................................................................................................................................... 17

SPARE PARTS LIST ....................................................................................................................................... 18


3

Introduction

Scope of the manual

This manual provides operation and maintenance instructions for model HPNM-100, HPNM-160, HPNM-250 and HPNM-500 hydrogen generators.

Specifications

Table 1 Specifications of the different models of hydrogen generator Hydrogen flow rate Model HPNM-100 0-100 cc/min at STP

Model HPNM-160 0-160 cc/min at STP



STP Standard temperature and pressure (STP)

20°C (68°F), 1 bar (14.5 psig)

Weight (dry) HPNM 100 - 160 - 250 17.5 kg (39 lbs)

HPNM 500 19 kg (42 lbs)

Power consumption Model NMH2-100 090 VA

Model NMH2-160 115 VA



Input voltage 110-230V / 50-60Hz

Fuse 4A (5x20) slow blow

Pressure accuracy 0.1 barg (1.5 psi) (± 0.5 %)

Microprocessor controlled display Graphic display, 128 x 64 pixels

Index of protection IP2x Operating conditions: - Temperature - Relative humidity

+15°C to +40°C (60°F to 104°F) 0-80%, non condensing

Over voltage category II

Pollution degree 2

Sound pressure level 46 dB(A)

Case dimensions 230 x 355 x 410 mm (9 x 14 x 16 in) (WxDxH)


4

Notes on FCC compliance

This equipment has been tested and found to comply with the limits for a Class B digital de-vice, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the re-ceiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

WARNING!

Any changes or modifications to this equipment not expressly approved by the manufac-turer may void the user's authority to operate the equipment.

Correct use

The Matheson Tri-Gas hydrogen generator is designed to produce hydrogen for laboratory use. The unit must only be operated for this purpose, according to the specifications and in-structions provided in this manual. In particular, the following warnings must be observed at all times:

• Indoor use only

• Never operate the unit in freezing temperatures (<32°F (0°C)). This will cause irre-versible damage to the electrolysis cell.

• Only use pure water (see “Filling the water tank”)

• Only operate the unit in a room with sufficient ventilation (see “Placing the unit”).

• Always unplug the unit from the mains power supply before accessing the internal components for replacement.

• Only the parts described in the “Spare parts list” can be replaced by the user.


5

Packing list

Table 2 List of items included in the shipment

Quantity Description

1 Hydrogen generator

1 Instruction manual

1 Deionizer bag

1 Water drain with flexible tubing

1 Power cable

Hydrogen Generator Instruction Manual Installation

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Description The hydrogen generator produces pure hydrogen (and oxygen as a by-product) by the elec-trolysis of water. The key element of the generator is an electrochemical cell assembly which contains a solid polymer electrolyte. No free acids or alkalines are used. De-ionized or pure, distilled water is the only liquid which may come into contact with the cell. As this is con-sumed it must be refilled from time to time as required. The generated hydrogen gas is accumulated in the hydrogen/water separator and the desic-cant housing. The internal pressure is controlled by a pressure transducer. The outlet pres-sure is controlled by a proportional valve. The hydrogen is dried by passing through the automatic dryer. The hydrogen then passes through outlet port at the rear.

WaterTank

H2 GLSlow

press.

H2 GLShigh

press.

O2 GLSlow

press.

Dryer

Cell

Int. Press. Sens.

Ext. Press. Sens.

H2 Pressure

relief

H2 Outlet

H2 Vent

O2 Vent

Drain port / Autorefill connector


7

Installation

Receiving the generator

All units have been carefully inspected before transport. Visual checks for damage and func-tional tests should be performed upon receipt. Any damage must be immediately noted and reported. The generator must only be returned according to the shipping instructions pro-vided.

Placing the generator

The hydrogen generator must be placed on a flat, level, vibration-free, shock-free surface. Do not place the generator over a source of heat, as this may cause the device to overheat. The unit should not be in contact with any other objects on any side, and the air inlet must not be blocked. Leave at least 30 cm (12 in) of free space at the rear for ventilation. Do not operate the generator in a sealed or unventilated room, or in close proximity to open flame or other sources of ignition. Do not operate the generator at below freezing tempera-tures. Operation is guaranteed at operating temperatures between +15 and +40°C(60°F to 104°F).

WARNING!

Normal precautions for any hydrogen supply should be taken when using the generator. DO NOT use in sealed or unventilated rooms. DO NOT use in close proximity of open

flames or other sources of ignition.

Symbols used on the generator

Earth symbol: This symbol marks the earth connections to the chassis of the hy-drogen generator.

Gas connections

Pure dry hydrogen at regulated pressure is available at the hydrogen outlet port at the rear of the generator. This port must be connected to 1/8" tubing using a stainless steel or copper Swagelok connector. Teflon connectors are not suitable. The pressure at this port is adjusted and shown on the display. The hydrogen relief port at the rear of the unit can be connected to an exhaust hood or other vent system.

WARNING!

The line from the relief port should never connected in such a way that back pressure can develop.


8

Electrical connections

Check the setting of the voltage selector on the rear of the unit. The set voltage is indicated by the white arrow. To change the voltage, proceed as follows:

• Using a small screwdriver, remove the voltage selector insert.

• Replace the voltage selector insert so that the white arrow points to the correct voltage.

Remote connections (optional)

The hydrogen generators are fitted with an optional remote control feature, which allows the user to check the status of the machine from a remote position, and to start/stop the produc-tion of hydrogen. The contacts used in the remote control are potentially free relay contacts. The contacts can be configured via software as normally-open or normally-closed (see the Configuration sec-tion). The maximum voltage and current ratings for the contacts are 1A / 48V. The pin con-figuration of the remote connector is shown in the table below.

Table 3 Remote connector pin configuration

Pin Description

1+2 Start (12-30 VDC polarity not important)

3+4 Standby (System not OK)

5+6 Reaching normal pressure (Overproduction)

7+8 Refill water (Low water)

09+10 Low water level (Too low water)

11+12 Bad water

13+14 Change water (Bad water pre alarm)

IMPORTANT! Remove the plugs from the oxygen vent and

hydrogen vent before operating the unit.

Keep these plugs for transporting the unit.

Hydrogen Generator Instruction Manual Operation

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Cascading (Option)

The RS-485 interface allows up to 10 generators to be operated in parallel mode. One unit has to be defined as the master, while the others operate in “Slave” mode. All the slaves need to be configured with individual ID numbers. Communication between the generators requires a standard D-sub 9 pin serial cable. The serial ports are connected as follows: Master RS 485 port 1 Slave 1 RS 485 port 1 - Slave 1 RS 485 port 2 Slave 2 RS 485 port 2 ……… Configuration For operation in cascading mode all generators must have an ID number. Each ID number is unique. The master unit must also have an ID number. Configuring the Master

1. Go into the configure menu and set the master to NO. 2. Go into the number of slaves menu and set the number off units connected to the

master. 3. Go into slave ID number and set the desired value. 4. Go back to master and set the value to yes

Configuring the Slaves

1. Go into the configure menu and set the master to NO. 2. Go into slave ID number and set the desired value.

The configuration is now complete. Operating in Master-Slave Mode If the configuration and the serial connection is correct, the slaves will show “Slave Mode“ when powered up. Connect the gas outlets of all the generators to the same line.

IMPORTANT!

The cascading function will only work properly if the gas outlets on all the generators are connected to the same gas line.


10

Initial start-up

Filling the water tank

To fill the water, remove the cap under the slider on the water tank. Carefully fill the tank with distilled or deionized water. The conductivity of the water used in the generator must not exceed 2µS (.5 Mohm). Fill the tank to the maximum level indicator. Close the slider cap.

WARNING!

Do not fill the water tank higher than the marked level.

CAUTION!

To prevent contamination of the cell assembly, it is important to use only deionized or dis-tilled water in the generator. Water containing metallic impurities will contaminate or dam-

age the cell, and will void the warranty.


11

Installing the deionizer bag

After having filled the tank with water, the deionizer bag (supplied) must be placed in the tank. Inspect the bag thoroughly for holes or tears, indicated by loose deionizer beads on the outer surface. If the bag is damaged in any way, discard and replace it with a new one. Only use original parts (see Spare Parts). Wash the deionizer bag in deionized water before pro-ceeding. Insert the free end of the “T” fastener through the hole in the centre of the water filler cap, un-til it is securely fastened. The bag should not block the outlet at the bottom of the tank. Once in place, the bag should not be allowed to dry out.


12

Operation

The operating status of the unit is shown on the main screen on the graphic display.

The main screen has three options at the bottom, corresponding to the three buttons on the unit, which are used to run the various functions and access the configuration and diagnos-tics of the unit, following the tree structure shown in the figure below.

scm

Exit

volume units Temp units

Exit

°F

0.5 bar/min

Exit

Pressure rise

On

Exit

Autostart

Beeper

Exit

On No

Exit

Master Number of slave

Exit

1

1

Exit

ID number Remote

Exit

Start/Stop Normaly close

Exit

Remote relay mode

lock keyboard

Exit

No 5

Exit

Prealarm in list Display contrast

Exit

5

120 s

Exit

Autorefill timeAutorefill

Exit

Off

Exitselectscroll

Temp units

Volume units

Exit

Pressure units

configure

Configure

Pressure units

Volume units

Temp units

Pressure rise

Pressure drop delay

Autostart

Number of slaves

Master

beeper

Pre alarms in list

lock keyboard

display contrast

Remote relay mode

Remote

ID number

Autorefill

Autorefill time

Bar

Exit

pressure units

Pressure drop delay

Exit

60 sec.

menùmenù

exit

Pressure Adjust

Configure

Utilities

scroll select

Pressure Adjust

Utilities

MenuOpenStart

Standby70 bar

barSet.Act.Press.

WaterFlow

Exit

pressure adjust

utilities

Alarm list

Diagnostic

Special functiones

Exitselectscroll

Exitselectscroll Exit

configure

Configure

10.7 bar

Temp units

Volume units

Pressure units


13

Menu tree for the operation of the unit

Special functions

DiagnosticUtilitiesutilities

Alarm list

Diagnostic

Special functiones

Exitselectscroll

Exit

alarm list

03.05.2004 17.00 Low pressure

12.05.2004 17.00 Low water

21.04.2004 17.00 Bad water

Prod. Tot.:

Oper. Time:

W. Quality:

diagnostic

Exit

µS

H

scm

scroll select Exit

Leak internal

Dryer

Release Pressure

Special functions

Prod. Tot.:

Oper. Time:

W. Quality:

Cell Vpeak:

Cell Volt:

Cell Curr.:

PS Temp.:

PS Tpeak:

Int. Press.: bar

°C

°C

A

A

V

µS

H

scm

Leak external

Flow test

Complete system

Leak internal

Dryer

Release Pressure

Start exit

releare pressure

77 bar

barOut Press.:Int. Press.:

selectscroll

heater test

dryer conditioning

dryer status

exit

dryer dryer conditioning

exit

exit

dryer status

°C

minute

°C

Cycle time:

Temp. Col.2:

Temp. Col.1:

Time:

Remaining:

Temp. Col.1: Temp. Col.1:

Remaining:

Time:

Temp. Col.2:

exit

heater test

Heater 1: StopHeater 2: StopStart

Int. Press.:Out Press.: bar

bar77

leak internal

exitStart

Start exit

leak external

77 bar


Int. Press.:Out Press.: bar

bar77

Flow test

exitStart

Wait Flow 0%exit

Flow test

77 bar


complete system test

exit

leak test

scroll select

Heater 1: stop

Heater 2: stop


14

Configure parameters Item Description Options / Range Default Pressure units Sets the desired unit of measure for

the pressure bar / psi / kPa bar

Volume units Sets the desired unit of measure for the volume

scm (standard cubic meters) scf (standard cubic feet)

scm

Temp. units Sets the desired unit of measure for the temperature

°C and °F °C

Pressure rise Sets how fast the pressure has to in-crease. If the pressure increases at a slower rate, a low pressure alarm is activated.

0.1 – 6.8 bar/min 1.4 - 100 psi/min

0.3 1.5

Pressure drop delay

Sets a delay in seconds to ignore a pressure drop (override low pressure alarm)

2 - 10 min 2

Auto start Sets whether the unit automatically starts production when power is switched on.

YES / NO NO

Beeper Sets whether the audible signal is ac-tivated in the event of an alarm.

ON / OFF ON

Master Configures the unit as the Master for cascading operation

YES / NO NO

Number of slaves

Enter the number of slaves con-nected to the master

0 - 32 0

ID number Sets the ID number 0 - 32 0 Remote start/stop mode

Configures the remote start/stop function

Start/stop, Start only, Direct control

start/stop

Remote relay mode

Configures the remote relay con-tacts.

Normally open (NO) Normally closed (NC)

NC

Pre alarms in alarm log

If set to Yes, the pre alarms are also shown in the alarm log.

YES / NO NO

Lock Keyboard If set to Yes, the keyboard will be locked automatically after the gen-erator is in the main window for more than 20s. To unlock the keyboard, press the unlock button and hold for 5s.

YES / NO NO

Display contrast Adjusts the contrast of the display. 0 - 10 5 Autorefill If set to ON, the pre-level water alarm

is used to trigger an external pump or valve to refill the water tank

ON / OFF OFF

Autorefill time Sets the duration of water refilling af-ter the pump or valve has been trigged

0-60 s 0


15

Diagnostic display Item Description Max. Production Tot. Total production of hydrogen 99.999 scf

4000.00 scm Operating time (h) Total number of hours the unit operation 99.999 hours Wat. quality (µS) Actual water conductivity - Cell current (A) Actual cell current - Cell voltage (V) Actual cell voltage - Cell voltage peak (V) The maximum cell voltage in the life of the cell - PS. temp. Actual temperature of the power supply - PS. temp. peak The maximum temperature of the power supply

reached -

Int. Press.: Actual internal pressure of the unit - Special functions Item Description Release pressure This function is used to depressurize the unit completely.(works only

in stand-by mode and gas line has to be removed) Dryer Accesses the dryer functions (see below) Dryer status Shows the temperatures of the drying columns and the position of the

cycle Conditioning When the conditioning cycle is started, the dryer performs 4 fast cy-

cles. During this time the output valve is closed. Heater test The heater has to show a reaction of 10°C to pass the test Leak internal The outlet valve is closed, the pressure is set to the max., when the

pressure reaches the max., production is stopped and the pressure drop is measured over 1 minute. If the pressure drop is below the preset value, the test is passed. Important: The leak test will only work if the generator is in standby mode.

Leak external Works similar to the leak internal except the outlet valve is open. This function can be used to test the external gas lines Important: The leak external will only work if the generator is in standby mode.

Complete system test Combination of leak internal and heater test Flow test This functions sets the outlet valve to provide a certain flow

Important: this function will only work if the generator is in standby mode. Adjustable from 0 to 100% of maximum flow.

Toggle Valve Used to switch the valves manually ( for advanced diagnostics only) Important : after exiting this window, the valves will return to the status prior to entering the window

Hydrogen Generator Instruction Manual Maintenance

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Maintenance With proper care and maintenance, your hydrogen generator should provide you with years of trouble-free operation. There are no adjustments to be made to the generator. The only routine service operations are those described below. Nonetheless, the generator should be inspected approximately every 2 years. Contact your supplier or Matheson Tri-Gas directly.

Routine maintenance

The following section describes the maintenance operations required for the correct opera-tion of the hydrogen generator. Cleaning The internal components of the hydrogen generator do not need to be cleaned and should not be accessed by the user for cleaning. To clean the outside of the unit, only use a damp cloth (no detergents, acids or aggressive or abrasive substances. Water refilling The tank must be refilled when the water level approaches the lower level, and the Refill Water pre-alarm message appears. Deionizer bag replacement Rinse the water tank and replace the deionizer bag approximately every six months, or whenever the Change Water message appears. Installing the new deionizer bag See page 12 (see Installing the deionizer bag)

Hydrogen Generator Instruction Manual Maintenance

17

Returning the unit

In the event of any faults or damage, first notify the agent or distributor who supplied the unit. If this is not possible, inform Matheson Tri-Gas directly. Please also provide full details of the problem, including the model and serial number. Instructions will then be provided for the service or the return of the unit. Only if return authorization is provided by Matheson Tri-Gas as per these instructions, will the device be received and repaired by Matheson Tri-Gas. If the one year warranty has expired, or the fault is due to misuse of the unit, all repair and shipping costs are to be paid by the customer. All other costs are borne by the customer, ex-cept as otherwise expressly agreed upon. Matheson Tri-Gas [email protected]

WARNING!

If the unit has to be transported, make sure that the water tank is completely empty, and place the plug (supplied with the unit) on the oxygen vent at the rear of the unit. Close the

water tank with the cap. Use suitable packaging. The unit should be transported in an upright position; this warning should be reported on

the outside of the packaging.

Hydrogen Generator Instruction Manual Spare parts list

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Spare parts list The table below provides a list and description of the spare parts of the hydrogen generator. Please also refer to the corresponding figures.

Table 4 List of spare parts

p/n DESCRIPTION MBAG-0222-XX DEIONIZER BAG

IMPORTANT!

The manufacturer reserves the right to change or modify its products without prior notice.

Hydrogen Generator Model HPNM – 2...Hydrogen Generator Instruction Manual Introduction 3 Introduction Scope of the manual This manual provides operation and maintenance instructions

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